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DOE OSTI2021

Time-dependent experimental identification of inter-ELM microtearing modes in the tokamak edge on DIII-D

In a series of discharges on the DIII-D tokamak, fast vertical plasma jogs are used to induce current perturbations in the steep gradient region of the H-mode edge. These current perturbations directly influence the edge q profile, decoupling the resonant location and instability drive of pedestal-localized microtearing modes (MTMs.) By exploiting this effect, we develop and apply a new experimental technique to track the dynamical frequency evolution of MTMs in the pedestal region, providing a compelling validation of the MTM model. The frequency of potential MTMs is calculated as the Doppler-shifted electron diamagnetic frequency at rational q=m/n surfaces, showing remarkable agreement with chirped frequency behavior of n=3, 4 and 5 modes detected with fast magnetics. Data is collected throughout multiple ELM cycles in order to build robust statistics describing the time-dependent frequency evolution of MTMs, which can be explained by examining the recovery of pedestal gradients after an ELM event. MTMs have a dominant transport contribution in the electron thermal channel, so the presented results indicate that reduced models of pedestal transport must be electromagnetic in nature and constructed with accurate calculations of MTM stability; inclusion of this physics is essential for accurate predictions of the electron temperature pedestal profile. Supporting measurements of mode saturation, propagation direction and transport fingerprints are made to support the dynamic frequency determination, unambiguously and experimentally identifying MTMs in the pedestal region of DIII-D.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2016

Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) Final Report

The Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) was a two-month effort, chartered by NASA, to provide timely inputs for mission requirement formulation in support of the Asteroid Redirect Robotic Mission (ARRM) Requirements Closure Technical Interchange Meeting held December 15-16, 2015, to assist in developing an initial list of potential mission investigations, and to provide input on potential hosted payloads and partnerships. The FAST explored several aspects of potential science benefits and knowledge gain from the ARM. Expertise from the science, engineering, and technology communities was represented in exploring lines of inquiry related to key characteristics of the ARRM reference target asteroid (2008 EV5) for engineering design purposes. Specific areas of interest included target origin, spatial distribution and size of boulders, surface geotechnical properties, boulder physical properties, and considerations for boulder handling, crew safety, and containment. In order to increase knowledge gain potential from the mission, opportunities for partnerships and accompanying payloads were also investigated. Potential investigations could be conducted to reduce mission risks and increase knowledge return in the areas of science, planetary defense, asteroid resources and in-situ resource utilization, and capability and technology demonstrations. This report represents the FASTâ€"TM"s final product for the ARM.

Mazanek, Daniel D.↗

DOE OSTI2021

Combined Mesonet and Tracker

Title: Combined Mesonet and Trackers (UNL Mobile Mesonets) Authors University of Nebraska PI: Adam Houston, UNL Professor (ahouston2@unl.edu) Mailing Address: 126 Bessey Hall P.O. Box 880340 Lincoln, NE 68588-0340 CoMeT Overview The University of Nebraska-Lincoln operates three Combined Mesonet and Tracker (CoMeTs). CoMeTs are Ford Explorers (model years 2015, 2017, and 2019) with forward-mounted suites of meteorological sensors and dual moonroofs, combining the capability of a mobile mesonet to collect near-surface observations with the capability of an unmanned aircraft systems (UAS) tracker vehicle, which enables an observer in the second row of seats to see the aircraft and maintain compliance with Federal Aviation Administration policies on UAS operation. The CoMeTs collect observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155A, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, and vehicle heading using a KVH Industries C-100 fluxgate compass (Barbieri et al. 2019). The HMP155A and 109SS-L thermistor are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). This list of sensors is also included in the CoMeT data file metadata. Manufacturer specifications for these instruments are given in Table 1 of Hanft and Houston (2018). The reported measured quantities are summarized below.CoMeT-3 was funded through an equipment allocation included in the NSF TORUS award (AGS-1824649). Instrument Description The specific sensors included on each CoMeT are summarized in the table at the end of this section. In general each CoMeT collects observations of slow temperature and humidity at ~2 m above ground level (AGL) using a Vaisala HMP155, fast temperature at ~2 m AGL using a Campbell Scientific 109SS-L thermistor, pressure at ~2.5 m AGL using a Vaisala PTB210 barometer with a Gill pressure port, wind speed and direction at ~3.25 m AGL using an R.M. Young 05103 propeller anemometer, position using a Garmin 19x HVS receiver, and vehicle heading using a KVH Industries C-100 fluxgate compass. The HMP155 and 109SS are shielded and aspirated within a U-tube (Waugh and Frederickson 2010; Houston et al. 2016). Fast temperature and corrected RH measurements (using sensors housed within the U-tube) have a time constant of 10-12 s based on data collected across a temperature and RH shock during the CLOUD-MAP 2017 calibration/validation tests on June 26, 2017. Vehicle speed was < 10 kts for this test. CoMeT-1 CoMeT-2 CoMeT-3 Slow Temperature Slow RH Vaisala HMP155A-L20-PT Part #: 22280-7 Vaisala HMP155E Part #: E1AA11A0B1A1A0A Vaisala HMP155E Part #: E1AA11A0B1A1A0A Fast temperature Campbell Scientific 109SS-L20-PT Part #: 21448-3 Campbell Scientific 109SS-L12-PW Part #: 21448-109 Campbell Scientific 109SS-L12-PW Part #: 21448-150 Pressure Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Vaisala PTB-210 Part #: A1A1B Gill Pressure Port Part #: 61002 Wind RM Young 05103-L20-PT Part #: 18435-310 RM Young 05103-L20-PW Part #: 18435-244 RM Young 05103-L20-PW Part #: 18435-244 GPS Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Garmin GPS 19x HVS (NMEA 0183) Part #: 010-01010-00 Compass KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 KVH C-100 Part #: 01-0177-15 Logger Campbell Scientific CR6-NA-XT-SW Part #: 28385-9 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Campbell Scientific CR6-WIFI-XT-SW Part #: 28385-6 Data Collection and Real-Time Processing The reported measured quantities are summarized in the table below. Quantity Units Source Epoch time Seconds GPS Latitude and longitude Degrees GPS Altitude m GPS Pressure hPa PTB210 Temperature (fast) deg C 109SS-L Temperature (slow) deg C HMP155 RH (slow) % HMP155 Vehicle speed m/s GPS Vehicle heading deg C-100 and GPS In addition to the measured variables, several derived variables are calculated. Corrected/fast relative humidity (%) Relative humidity is adjusted to the fast temperature following Richardson et al. (1998) and Houston et al. (2016). Water vapor mixing ratio (g/kg) Dew point temperature (°C) Potential temperature (Kelvin) Virtual potential temperature (Kelvin) Equivalent potential temperature (Kelvin) Regular intercomparisons between all three CoMeTs were performed during TORUS 2019. Comparisons were also conducted between CoMeT-1 and CoMeT-2 during LAPSE-RATE (2018) on 14 July. In these intercomparisons, the vehicles were parked adjacent to each other aligned perpendicular to (and facing into) the wind. To minimize engine heating effects, intercomparisons were only conducted when the wind speed was >10 kts. Data Format Original data files for each deployment are saved as text files and then converted to NetCDF. NetCDF versions have units that are CF compliant and may not match the original units in the txt files. The naming convention for the NetCDF files is as follows: UNL.CoMeT3.{deployment date YYYYMMDD}.{start time of observation collection in UTC HHMM}.L2.{post-processing codes}.cdf example: UNL.CoMeT3.20190627.1931.L2.g1.f1.cdf Post-processing codes are included to track modifications to the raw data. These codes are closely connected to error flags associated with each record. Each letter corresponds to a particular instrument: g: GPS p: Barometer tf: Fast temperature ts: Slow temperature rh: Relative humidity f: Compass w: Wind monitor a: All instruments Each number corresponds to a particular post-processing action described more below. Measured and derived variables are included in the following table. Variable Heading Standard Name Units time Time seconds since 00:00:00, 01-01-1970 Alt Altitude meters lat Latitude degrees north lon Longitude degrees east fast_temp Air Temperature kelvin slow_temp Air Temperature kelvin pressure Air Pressure pascals logger_RH Relative Humidity percent calc_corr_RH Relative Humidity percent wind_speed Wind Speed meters per second wind_dir Wind From Direction degrees vehicle_dir Vehicle Direction degrees dewpoint Dew Point Temperature kelvin mixing_ratio Humidity Mixing Ratio g/g theta Air Potential Temperature kelvin theta_v Virtual Potential Temperature kelvin theta_e Equivalent Potential Temperature Kelvin error_flag The error_flag variable is a string that matches the post-processing codes listed above. All instruments will have an associated code, but will have a “0” if the datum is unchanged from the initial processed value. Error Codes The following table summarizes the error codes for data collected before 2020: Error Code Relevant CoMeT Description g1 1,2,3 Exact correction. GPS position and time reprocessed from raw data g2 1 As far as we can tell this is an exact correction to an error in the GPS time. During the correct time periods the time suddenly went backwards ~250s and stayed at this offset for 750s when it corrected itself. The offset was applied to the “time warp” period. p1 2 Approximate correction. Hole in the pressure tube connecting the pressure port to the barometer. Resulted in erroneously low air pressure measurements when the vehicle was in motion. Derived variables recalculated (dew point temperature [e depends on qv and p], water vapor mixing ratio, potential temperature, virtual potential temperature, equivalent potential temperature) a1 3 Exact correction. Missing data reprocessed from raw data a2 1 Bug fix to bias correction for ts1, ts2, and rh1: water vapor mixing ratio was off by a factor of 10 and virtual potential temperature was wrong because of this. f1 3 No correction, missing data. Fluxgate compass inoperable. Wind speed and direction calculated using GPS-derived vehicle heading instead. rh1 1 Approximate correction. Constant bias of +1.7% removed from relative humidity. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts1 1 Approximate correction. Constant bias of +0.6 K removed from slow temperature. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) ts2 1 Approximate correction. Constant bias of +1.0 K removed. Derived variables recalculated (corrected/fast relative humidity, dew point temperature, water vapor mixing ratio, virtual potential temperature, equivalent potential temperature) References Bolton, D., 1980: The Computation of Equivalent Potential Temperature. Mon. Wea. Rev., 108, 1046–1053, https://doi.org/10.1175/1520-0493(1980)108<1046:TCOEPT>2.0.CO;2. Hanft, W., and A. L. Houston, 2018: An Observational and Modeling Study of Mesoscale Air Masses with High Theta-E. Mon. Wea. Rev., 146, 2503–2524, https://doi.org/10.1175/MWR-D-17-0389.1.Wexler Houston, A. L., R. J. Laurence III, T. W. Nichols, S. Waugh, B. Argrow, and C. L. Ziegler, 2016: Intercomparison of unmanned aircraft-borne and mobile mesonet atmospheric sensors. Journal of Atmospheric and Oceanic Technology. 33, 1569-1582, doi: 10.1175/JTECH-D-15-0178.1. Lowe, P. R., 1977: An Approximating Polynomial for the Computation of Saturation Vapor Pressure. J. Applied Meteorology, 16, 100–103. Richardson, S. J., S. E. Frederickson, F. V. Brock, and J. A. Brotzge, 1998: Combination temperature and relative humidity probes: Avoiding large air temperature errors and associated relative humidity errors. Preprints, 10th Symp. On Meteorological Observations and Instrumentation, Phoenix, AZ, Amer. Meteor. Soc., 278–283. Waugh, S., and S. E. Frederickson, 2010: An improved aspirated temperature system for mobile meteorological observations, especially in severe weather. 25th Conf. on Severe Local Storms, Denver, CO, Amer. Meteor. Soc., P5.2. [Available online at https://ams.confex.com/ams/25SLS/techprogram/paper_176205.htm.]

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1987

Implementation of a digital optical matrix-vector multiplier using a holographic look-up table and residue arithmetic

The design and implementation of a digital (numerical) optical matrix-vector multiplier are presented. The objective is to demonstrate the operation of an optical processor designed to minimize computation time in performing a practical computing application. This is done by using the large array of processing elements in a Hughes liquid crystal light valve, and relying on the residue arithmetic representation, a holographic optical memory, and position coded optical look-up tables. In the design, all operations are performed in effectively one light valve response time regardless of matrix size. The features of the design allowing fast computation include the residue arithmetic representation, the mapping approach to computation, and the holographic memory. In addition, other features of the work include a practical light valve configuration for efficient polarization control, a model for recording multiple exposures in silver halides with equal reconstruction efficiency, and using light from an optical fiber for a reference beam source in constructing the hologram. The design can be extended to implement larger matrix arrays without increasing computation time.

Habiby, Sarry F.↗

DOE OSTI2025

Bounce-averaged theory in arbitrary multi-well plasmas: solution domains and the graph structure of their connections

Bounce-averaged theories provide a framework for simulating relatively slow processes, such as collisional transport and quasilinear diffusion, by averaging these processes over the fast periodic motions of a particle on a closed orbit. This procedure dramatically increases the characteristic time scale and reduces the dimensionality of the modelled system. The natural coordinates for such calculations are the constants of motion (COM) of the fast particle motion, which by definition do not change during an orbit. However, for sufficiently complicated fields – particularly in the presence of local maxima of the electric potential and magnetic field – the COM are not sufficient to specify the particle trajectory. In such cases, multiple domains in COM space must be used to solve the problem, with boundary conditions enforced between the domains to ensure continuity and particle conservation. Previously, these domains have been imposed by hand, or by recognising local maxima in the fields, limiting the flexibility of bounce-averaged simulations. Here, we present a general set of conditions for identifying consistent domains and the boundary condition connections between the domains, allowing the application of bounce-averaged theories in arbitrarily complicated and dynamically evolving electromagnetic field geometries. We also show how the connections between the domains can be represented by a directed graph, which can help to succinctly represent the trajectory bifurcation structure.

fusion plasma↗

DOE OSTI2020

TDCOSMO: II. Six new time delays in lensed quasars from high-cadence monitoring at the MPIA 2.2m telescope

In this paper we present six new time-delay measurements obtained from $R_c$-band monitoring data acquired at the Max Planck Institute for Astrophysics (MPIA) 2.2 m telescope at La Silla observatory between October 2016 and February 2020. The lensed quasars HE 0047–1756, WG 0214–2105, DES 0407–5006, 2M 1134–2103, PSJ 1606–2333, and DES 2325–5229 were observed almost daily at high signal-to-noise ratio to obtain high-quality light curves where we can record fast and small-amplitude variations of the quasars. We measured time delays between all pairs of multiple images with only one or two seasons of monitoring with the exception of the time delays relative to image D of PSJ 1606–2333. The most precise estimate was obtained for the delay between image A and image B of DES 0407–5006, where $τ_{AB} = –128.4_{–3.8}^{+3.5}$ d (2.8% precision) including systematics due to extrinsic variability in the light curves. For HE 0047–1756, we combined our high-cadence data with measurements from decade-long light curves from previous COSMOGRAIL campaigns, and reach a precision of 0.9 d on the final measurement. The present work demonstrates the feasibility of measuring time delays in lensed quasars in only one or two seasons, provided high signal-to-noise ratio data are obtained at a cadence close to daily.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1977

Pioneer 9 and Pioneer 10 observations of the solar wind associated with the August 1972 events

Observations are presented of the changes in the solar wind proton parameters at 0.8 and 2.2 AU as a result of the solar flares in August 1972. These observations were obtained by the NASA Ames Research Center solar wind plasma analyzer experiments on Pioneer 9 and Pioneer 10. High time resolution measurements are presented of the solar wind proton speed associated with the arrival of the interplanetary shocks at Pioneer 9 and Pioneer 10. For these events, differential ion energy per unit charge spectra are shown which indicate the changes in the solar wind ion distribution function associated with the arrival of each of the interplanetary shocks. Four fast shocks are identified at Pioneer 9, and it is found that previously the time of arrival of the first interplanetary shock at Pioneer 9 was not correctly identified. Two fast shocks and one reverse shock are identified at Pioneer 10.

Intriligator, D. S.↗

DOE OSTI2025

Quantifying Impacts of Biomass Pelletization on Fast Pyrolysis Using a Single-Particle Reactor, X-ray Computed Tomography, and Computational Modeling

The pore structure and density of lignocellulosic feedstocks dictate intraparticle transport phenomena and thereby play an important role in thermochemical conversion processes such as fast pyrolysis for biofuel and biochemical production. Variations in microstructure are inherent from different biomass species and can be introduced by preprocessing techniques such as cutting and pelletization. Morphological changes also occur during conversion and lead to vastly different pore structures and behavior during pyrolysis, which impact required conversion times and product distributions. The current work presents a comprehensive comparison of fast pyrolysis of neat and pelletized pine feedstocks, which includes single-particle experiments, modeling, and 3D imaging by X-ray computed tomography (XCT). The particle-scale model included anisotropic heat and mass transport in a shrinking particle with pyrolysis reactions based on the CRECK mechanism with boundary conditions informed by reactor-scale simulations of the single-particle reactor. The models were validated by measurements of the temperature and mass loss from single-particle pyrolysis experiments of neat and pelletized pine. Quantitative analysis of XCT geometries revealed that pyrolytic conversion yielded chars with increased porosity and permeability compared to the unpyrolyzed materials, along with decreased tortuosity and anisotropy. Pelletization of the pine feedstock resulted in a much denser, less permeable material, which converted slower and produced more residual char after pyrolysis compared to neat pine. The results from particle modeling revealed that accounting for the dynamic and anisotropic heat and mass transport caused by differences in pore structure is critical to achieving agreement with experimental results. Overall, this study highlights the dramatic differences in conversion behavior imparted by pelletization and the importance of capturing microstructural attributes in computational models to guide the design and optimization of pyrolysis processes for specific biomass feedstocks.

09 BIOMASS FUELS↗

DOE OSTI2021

On the relation between active-region lifetimes and the autocorrelation function of light curves

ABSTRACT Rotational modulation of stellar light curves due to dark spots encloses information on spot properties and, thus, on magnetic activity. In particular, the decay of the autocorrelation function (ACF) of light curves is presumed to be linked to spot/active-region lifetimes, given that some coherence of the signal is expected throughout their lifetime. In the literature, an exponential decay has been adopted to describe the ACF. Here, we investigate the relation between the ACF and the active-region lifetimes. For this purpose, we produce artificial light curves of rotating spotted stars with different observation, stellar, and spot properties. We find that a linear decay and respective time-scale better represent the ACF than the exponential decay. We therefore adopt a linear decay. The spot/active-region time-scale inferred from the ACF is strongly restricted by the observation length of the light curves. For 1-yr light curves our results are consistent with no correlation between the inferred and the input time-scales. The ACF decay is also significantly affected by differential rotation and spot evolution: strong differential rotation and fast spot evolution contribute to a more severe underestimation of the active-region lifetimes. Nevertheless, in both circumstances the observed time-scale is still correlated with the input lifetimes. Therefore, our analysis suggests that the ACF decay can be used to obtain a lower limit of the active-region lifetimes for relatively long-term observations. However, strategies to avoid or flag targets with fast active-region evolution or displaying stable beating patterns associated with differential rotation should be employed.

Santos, A. R. G. (ORCID:0000000171956542)↗

NASA NTRS2019

Fast Attitude Maneuvers for the Lunar Reconnaissance Orbiter

This paper describes a new operational capability for fast attitude maneuvering that is being developed for the Lunar Reconnaissance Orbiter (LRO). The LRO hosts seven scientific instruments. For some instruments, it is necessary to per-form large off-nadir slews to collect scientific data. The accessibility of off-nadir science targets has been limited by slew rates and/or occultation, thermal and power constraints along the standard slew path. The new fast maneuver (FastMan) algorithm employs a slew path that autonomously avoids constraint violations while simultaneously minimizing the slew time. The FastMan algo-rithm will open regions of observation that were not previously feasible and improve the overall science return for LRO's extended mission. The design of an example fast maneuver for LRO's Lunar Orbiter Laser Altimeter that reduc-es the slew time by nearly 40% is presented. Pre-flight, ground-test, end-to-end tests are also presented to demonstrate the readiness of FastMan. This pioneer-ing work is extensible and has potential to improve the science data collection return of other NASA spacecraft, especially those observatories in extended mission phases where new applications are proposed to expand their utility.

Karpenko, Mark↗

NASA NTRS2010

Goal Selection for Embedded Systems with Oversubscribed Resources

We describe an efficient, online goal selection algorithm and its use for selecting goals at runtime. Our focus is on the re-planning that must be performed in a timely manner on the embedded system where computational resources are limited. In particular, our algorithm generates near optimal solutions to problems with fully specified goal requests that oversubscribe available resources but have no temporal flexibility. By using a fast, incremental algorithm, goal selection can be postponed in a "just-in-time" fashion allowing requests to be changed or added at the last minute. This enables shorter response cycles and greater autonomy for the system under control.

Rabideau, Gregg↗

NASA NTRS2010

Onboard Run-Time Goal Selection for Autonomous Operations

We describe an efficient, online goal selection algorithm for use onboard spacecraft and its use for selecting goals at runtime. Our focus is on the re-planning that must be performed in a timely manner on the embedded system where computational resources are limited. In particular, our algorithm generates near optimal solutions to problems with fully specified goal requests that oversubscribe available resources but have no temporal flexibility. By using a fast, incremental algorithm, goal selection can be postponed in a "just-in-time" fashion allowing requests to be changed or added at the last minute. This enables shorter response cycles and greater autonomy for the system under control.

Rabideau, Gregg↗

NASA NTRS2009

Tractable Goal Selection with Oversubscribed Resources

Rabideau, Gregg↗

NASA NTRS1978

Circadian rhythm dissociation in an environment with conflicting temporal information

The relative contributions of light-dark (LD) cycles and eating-fasting (EF) cycles in providing temporal information to the circadian time-keeping system were examined in chair-acclimatized squirrel monkeys (Saimiri sciureus). The circadian rhythms of drinking, colonic temperature, urine volume, and urinary potassium excretion were measured with the LD and EF cycles providing either conflicting phases or periods. In conflicting phase experiments, animals were exposed to 24-hr LD cycles consisting of 12 hr of 600 lx followed by 12 hr of less than 1 lx and concurrent 24-hr EF cycles in which the animals ate for 3 hr and then fasted for 21 hr. One group had food available at the beginning and a second group at the end of the light period. In conflicting period experiments, monkeys were exposed to 23-hr LD cycles and 24-hr EF cycles. Analysis of the rhythms showed that both phase and period information were conveyed to the drinking and urinary rhythms by the EF cycle, and to the temperature rhythm by the LD cycle.

Sulzman, F. M.↗

NASA NTRS2004

Control and Identification of Turbulent Boundary Layer Separation

Effective delay of turbulent boundary layer separation could be achieved via closed-loop control. Constructing such a system requires that sensor data be processed, real-time, and fed into the controller to determine the output. Current methods for detection of turbulent boundary layer separation are lacking the capability of localized, fast and reliable identification of the boundary layer state. A method is proposed for short-time FFT processing of time series, measured by hot-film sensors, with the purpose of identifying the alternation of the balance between small and large scales as the boundary layer separates, favoring the large scales. The method has been validated by comparison to other criteria of separation detection and over a range of baseline and controlled flow conditions on a simplified high-lift system, incorporating active flow control.

Seifert, Avi↗

DOE OSTI2021

Optimized Carbon Fiber Intermediate Development to Enable High-Volume Manufacturing of Lightweight Automotive Composites

The ongoing pursuit of improved fuel economy and reduced greenhouse gas emissions has resulted in sustained interest for lightweight materials technologies. In this context, carbon fiber composites have captured the imagination of automotive engineers due to the potential to achieve substantial mass reduction when compared to traditional steel construction. That stated, the use of carbon fiber composites in automotive has been limited for the most part to premium supercars and other derivative platforms. In these cases, manufacturing costs are less of an obstacle to implementation, and the performance benefits of carbon fiber have enabled production of structures offering more than 50% weight savings. In practice, translating these low-volume demonstrations onto high-volume vehicle platforms has remained challenging. This can be attributed to several factors, with the absence of suitable high throughput production methodologies being a key impediment. To date, structural, crash critical components have relied upon manufacturing techniques born out of the aerospace industry. This has created a disconnect between automotive production systems that are accustomed to manufacturing multiple parts per minute and the aerospace technologies that have cycle times in the order of hours. Consequently, the focus of this project is the development of manufacturing process technology for carbon fiber composites that can support a mainstream vehicle program at an assumed throughput of 100,000 vehicles per year. In practice, this translates to a part-to-part cycle time of less than 3 minutes. Project participation included contributions from a broad range of academic, industrial and national lab partners. The primary scope of work, being the development of new carbon fiber epoxy compounds that are stable at room temperature and suited to high throughput automated processing. For project management, the work streams were divided into six key areas, with the lead organization in parentheses. • Carbon fiber/epoxy materials formulation development and scale up (Dow) • Simulation of discontinuous near isotropic meso-structure intermediates (Purdue) • Simulation of mechanical performance of compression molded components (Purdue) • Meso-Scale morphological analysis and correlation with structural performance (UTK) • Paint and adhesion durability analysis (MSU) • Demonstrator part design, prototype production, and validation testing (Ford). The primary goal at the commencement of the project was development of a chopped carbon fiber sheet molding compound (SMC) that offered a three times improvement in tensile modulus over a comparable glass-based SMC. In addition to meeting mechanical performance targets, the resin kinetics were modified to achieve a processing cycle time of less than 3 minutes. Other critical-to-quality (CTQ) specifications were also stipulated to account for a broad range of materials and processing characteristics. To achieve the above, staff scientists at Dow Chemical created an extensive series of new epoxy blends for testing and validation. Throughout this development, a key challenge was attaining material performance goals without impacting processing behavior and paintability of finished components. The latter required a new internal mold release system being developed by Dow that was designed to complement the kinetics of the rapid cure epoxy. As a complement to work studies at the industrial partners, the teams from academia executed a series of analytical and experimental studies to investigate potential factors influencing CF-SMC performance. Unit cell models were developed to capture the meso-scale representations of the fiber matrix architecture. Results of this analysis and subsequent morphological investigations led to the design of a novel composite derivative comprising carbon fiber platelets embedded in an epoxy matrix; the platelet size and aspect ratio playing significant role in final composite properties. This approach was a departure from previous research in CF-SMC development whereby bulk filamentization or disassembly of the carbon fiber rovings had been considered the most effective means of achieving both fiber wet through and wet-out. As the course of the academia studies progressed, the aspect ratio of the fiber constituents was further optimized before finalizing material attributes and processing conditions. For the purposes of technology validation, the Ford team led a work stream devoted to the design, fabrication and testing of demonstration components. The carbon fiber SMC material has the potential to displace numerous stampings and castings on an automotive structure but ultimately vehicle closure applications were selected to showcase the abilities of the CF-SMC to achieve both mass reduction and business case for large complex structures. Using target properties established by the Dow staff scientists, the complete closure system for a full-size sedan decklid and a mid-size wagon liftgate were engineered. Prototypes for both applications were fabricated using production representative processing methods to allow for physical testing and performance validation of the CF-SMC structures. Following completion of a testing program that concluded with a FMVSS301 55 mph offset rear crash, the CF-SMC formulation was declared by the Ford team to have met all engineering requirements. To summarize, the joint development activities during this project led to significant technical breakthroughs and achievement of all milestones. The result was the development of a novel, tack-free carbon fiber molding compound that is suited to automated processing. This combined room temperature stability, fast cure kinetics, and internal mold release system facilitates cycle times that are conducive to high-volume production. The VORAFUSE M6400 successfully passed technology validation at Ford and is now eligible for consideration on future production commercial vehicle programs.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A fast two-stage algorithm for non-negative matrix factorization in smoothly varying data

This article reports the study of algorithms for non-negative matrix factorization (NMF) in various applications involving smoothly varying data such as time or temperature series diffraction data on a dense grid of points. Utilizing the continual nature of the data, a fast two-stage algorithm is developed for highly efficient and accurate NMF. In the first stage, an alternating non-negative least-squares framework is used in combination with the active set method with a warm-start strategy for the solution of subproblems. In the second stage, an interior point method is adopted to accelerate the local convergence. The convergence of the proposed algorithm is proved. The new algorithm is compared with some existing algorithms in benchmark tests using both real-world data and synthetic data. Furthermore, the results demonstrate the advantage of the algorithm in finding high-precision solutions.

interior point method↗

DOE OSTI2020

Counting of Hong-Ou-Mandel Bunched Optical Photons Using a Fast Pixel Camera

The uses of a silicon-pixel camera with very good time resolution (∼nanosecond) for detecting multiple, bunched optical photons is explored. We present characteristics of the camera and describe experiments proving its counting capabilities. We use a spontaneous parametric down-conversion source to generate correlated photon pairs, and exploit the Hong-Ou-Mandel (HOM) interference effect in a fiber-coupled beam splitter to bunch the pair onto the same output fiber. It is shown that the time and spatial resolution of the camera enables independent detection of two photons emerging simultaneously from a single spatial mode.

47 OTHER INSTRUMENTATION↗